JETIR Research Journal

© 2019 JETIR May 2019, Volume 6, Issue 5 www.jetir.org (ISSN-2349-5162)

JETIRBZ06059 Journal of Emerging Technologies and Innovative Research (JETIR) www.jetir.org 377

DESIGN AND FABRICATION OF

AUTOMATIC GEAR SYSTEM USING

ELECTROMAGNETIC VALVES

Rahul Pattar1 , Shubham Angadi2 , Dileep Kumar3 , Jummanna Bhangi4 , Srinivas S5

School of Mechanical Engineering REVA University

Rukmini Knowledge Park, Kattigenahalli Yelahanka, Bangalore, India

Abstract: - Vehicles are commonly used around the world particularly in INDIA. The gear shifting mechanism of the motor-cycle

is used manual. This work covers development of an indigenous gear shifting /changing system for all methods of motorcycle. By

this system the mechanical gear shifting will remain unchanged because an additional electromagnetic valves system is placed on

top of the lever, to shift the gear and automatically control the clutch. Electromagnetic valves made up of solid copper wire. By

using this system accurate control of the vehicle is achieved by varying the speeds. A wiper motor is used to control the position of

the clutch. Hardware, Software and testing of the electromagnetic valve are verified. System is flexible and can be used with any

motorcycle having manual transmission system. In this work the expected force for each electromagnetic valve was found to be 38.423 N. The effectiveness in gear operation between manual and electromagnetic valve were exactly the same and hence this

reduced the human effort.

Keyword: - Electromagnetic valves, Wiper motor, Relay, Speed sensor, Gear etc …..

I. INTRODUCTION

There are already some inventions done on gear box for motorcycle to transmit the torque from engine crankshaft to the

rear wheel of the motorcycle. The gear box is used to vary the torque as per the different driving conditions. The gearbox increases

the required torque for starting the vehicle. After the start or the running of the motorcycle there is no need of high torque, so now

gear box will transmit the optimum torque to the rear wheel at high speed. For the operation of gearbox and shifting the gear there

is need of some effort by the driver of motorcycle. A foot lever is used to shift the gears in a motorcycle. Also, a clutch is placed

between the engine and the transmission in order to engage and disengage the flywheel with the transmission. So for smooth driving of motorcycle there is need to time these two operations perfectly. This gear shifting becomes a tiresome process for most new

drivers. This can also help in reducing accidents.

An electronic gear-shifting system is a method of changing gears on a bike, which enables riders to shift with electronic switches

instead of using conventional control levers and mechanical cables. The switches have been connected by wires to a battery pack

and to a small electric motor that drives the derailleur, switching the chain from electrical to mechanical stem is to change gears

faster, and because the system does not use boden cables and can calibrate itself, it may require less maintenance.

In automatic gear changing we are going to use the electromagnetic valves to shift the gear .when the front electromagnetic valve pulls the gear will shift to upper gear and when the rear electromagnetic valve pulls the gear shift to lower gear . It is controlled by

the microcontroller and relay which is connected to the 12V 7Amph battery. The IR sensor is fixed to rear wheel which senses the

speed from the wheel and sends signals through microcontroller to control the speed of vehicle.

2 GENERAL COMPONENTS

2.1 Electromagnetic valve It is used to store the rotation kinetic energy. An electromagnet coil is formed when insulated solid copper wire is wound

around a core or form to create magnetic field it has primary coil and secondary coil were in due to the variation of charges in

electromagnetic coil EMF is generated. Its works on henrys law of mutual induction.

Fig 1: Electromagnetic valves

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2.2 Electronic speed sensor

The IR speed sensor was initially used to replace the mechanical linkage from the road wheels to the speedometer

eliminating cable breakage and simplifying the gauge construction (elimination all moving parts except for the needle/spring

assembly) the sensor also provided wheel peed data to the controllers to assist the operator in maintaining control of the vehicle.

The vehicle Speed sensor is also used for the proper shifting up of gears for the vehicle maintenance. It senses the speed from the

rear wheel and sends to the microcontroller to change the speed.

Fig 2: IR sensor

2.3 Microcontroller

A consist of processor core, memory and input and output devices in this ferroelectric RAM is included along with RAM.

Microcontroller is designed for various electronic applications including personal computer or various storage devices. Further

microcontroller and its products are used in various field such as automobile and implantable medical devices and various tool

operating device such as micro drill bit and micro tools. This microcontroller reduces the cost and basically uses separate

microprocessor and interacting devices. Now a day’s mixed signal controller is common and hence we required integration analog

components need to control other non digital system

Fig 3: Microcontroller

Speed range Gear position

10 sec after starting vehicle 1st gear

10-20 2nd gear

20-35 3rd gear

35& above 4th gear Table 1: Gear changing with respect to RPM

2.4 Lead acid battery

Since heat is measure source were in electrolyte evaporates due to increases in surfaces area and leading to formation of sulphate this lead acid battery increasing corrosion rate with temperature. And hence the life of battery in increases.

Whenever there is failure of the vehicle. additional flat battery can be used to increases the power were in the engine can

be throttled and hence due to this running of this engine can be resume hence in order to increases the life of these electromagnetic

valve lead acid battery as preferred.

Fig 4: Battery




2.5 Wiper motor

Wiper motors are devices in the wiper system that functions on a power supply in order to move the wiper blades in a

smooth motion. Like other motors, the wiper motor rotates continuously in one direction which is converted into a back and forth

motion.

The circuit maintains power to the wipers until they are parked at the bottom of the windshield, and then cuts the power to

the motor. This circuit also parks the wipers between wipes when they are on their intermittent setting

Fig 5: Wiper motor

2.6 Relay

Is basically used to operate a switch by using an electromagnetic. It is used control circuit by low power signal or several

such low signals by single control relay. Relays are used in telegraph circuit as amplifies in present work we are using four relay

out of which two relay are used for clutch and other two relay for gears

.

Fig 6: Relays

2.7 LCD Display

A liquid-crystal display is a flat-panel display or other electronic visual display that uses the light-modulating properties of liquid

crystals do not emit light directly. The LCD display is used in this system is to display the speed and gear shifting in the vehicle. It

displays the RPM and gear.

Fig 7: LCD Display




PIN SYMBOL FUNCTION

1 VSS GROUND

2 VDD SUPPLY VOLTAGE

3 VO CONTRAST SETTING

4 RS REGISTER SELECT

5 R/W READ/WRTE SELECT

6 EN CHIP ENABLE SIGNAL

7-14 DBO-DB7 DATA LINES

15 A/Vee GROUND FOR BACK LIGHT

16 K VCC FOR BACK LIGHT

Table:-2 LCD Display pins

3 OBJECTIVES AND METHODOLOGY

3.1 Methodology

In this automatic gear changing system we are used electromagnetic valves, relay, IR sensor, wiper motor, microcontroller,

LCD display and 12V battery . When the vehicle starts the battery will supply the power to the electric system. The microcontroller

will send the signal to the relay to actuate the electromagnetic valves. 10sec after starting the engine the electromagnetic valve pull

the gear and it shift the gear up and the vehicle will start running. After that IR sensor will sense the speed of the vehicle and send

it to the microcontroller to change the gear. In the mean time the microcontroller will send the signal to relay to activate the wiper motor to control the clutch. When we have to shift the gear the wiper motor will control the clutch .The vehicle is fully controlled

by the microcontroller and IR sensor.

Battery

Speed sensor

Electromagnetic valve 1 Electromagnetic valve 2 Wiper motor

Gear box Clutch

Microcontroller




3.2 Objectives:

To control the position of the clutch and gear system using electromagnetic valves

To calculate the required mechanical force to be applied for the electromagnetic valves

To program the entire operation using Ardinuo software for microcontroller

3.3 Literature review

1. Muttu raj, bharat kirupahar (1) worked on button operated electromagnetic gear changer for two wheeler four stroke

petrol engine. In his field of work they have used sealed lead acid battery, spring air pilot solenoid actuator and energy dissipator.

It uses two electromagnetic coils which are fixed to the gear shaft of two ends. One end is used to shift the gear in upward direction

and another one for downward direction these two coils are operated depending upon the speed of vehicle. In this work they have

obtained a smooth operation with minimal cost. The disadvantage was regarding the cost of equipment and hence new technology

has been implemented.

2. Mr.Mayuresh N.Pote (2) has worked on automated gear transmission in two wheelers using embedded system. In this system they have used proximity sensor, LCD display, relay, microcontroller and stepped DC motor. By using this kind of system

he was able to get a comfortable and a better control gear changing system.

3. Ambar gupta and Kundan kumar [3] worked on automatic gear shifting mechanism in two wheelers. In this they have

used sensor, actuators, servo motors and linear punching actuators. By using this setup and conducting the experiment they have

concluded that there is assembly of automatic gear box and the cost of installation is less.

4 MANUFACTURING AND DESIGN

4.1 ELECTROMAGNETIC VALVES AND PEDAL

The electromagnetic valves are coupled with the gear pedal by using nut and bolts by using spanner which is used to shift the gear

upward or downward by supplying the power the 12V battery.

4.2 ELECTRONIC CIRCUIT

In this system electric circuit is down by using relay, IR sensor, microcontroller, electromagnetic valves and battery. Four relay are

connected to microcontroller to change the gear and control the clutch which is operated by the 12V battery. The LCD display is

used to display the RPM and the gear which is connected to the microcontroller. The electronic components are fixed on the board

and it is fixed to the vehicle.

5 Experimental works

Fig 8: Experimental setup

The two electromagnetic valves are used to shift the gear. One is fixed to shift the gear to increase the speed. Another one is fixed

to shift the gear to reduce the speed. These two valves are operated depends upon the speed of the vehicle this is automatically

operated by electromagnetic valves to change the gear in two wheeler.

To perform an automatic gear changing system of a two wheeler and a method to controlling such apparatus. A power output of an

internal combustion engine is connected to drive wheels of the automobile. The microcontroller is connected to the electromagnetic

valves via relay. When the speed is increased the sensor will sense the speed and send to the microcontroller. Hence the microcontroller will change the gear as per the required speed. The clutch is operated by the wiper motor. When the speed of vehicle

is wearied hence the microcontroller will operate the wiper motor to pull the clutch via relay. Hence vehicle is operated fully

automatically.




SR. NO COMPONENTS

1 Voltage regulator 12V to 5V

2 LCD Display

3 Microcontroller

4 2 Relay to shift gears

5 2 Relay to control clutch

Table-3: Components in the circuit

6 RESULTS

In this project we are going to show that how the Automatic and manual gears are changed as per the required speed of

the vehicle. In manual gear changing system we are checking the speed of vehicle to change the gears. But in the

automatic gear changing system we are fixing the IR sensor to the rear wheel to sense the speed of the vehicle. For changing the first gear is automatically without sensing any speed. After first gear we are going to sense the speed of

vehicle and it is automatically changed the gear by using electromagnetic valves. Microcontroller will change the gear

as per the required speed of the vehicle. This is the working principle of the Automatic gear changing system using electromagnetic valves. The result is shown in the table 6.1 and 6.2 above.

6.1 For shifting gear to higher speed:

Field test result

SR no Initial gear Manual gear

Changing

Automatic gear changing Gear changing

Pulses in sec Speed in km/hr From To

1 FIRST 15 14 13 1ST 2ND

2 SECOND 25 25 22 2ND 3RD

3 THIRD 32 33 30 3RD 4TH

4 FOURTH No shifting 38 35 NO SHIFTING

Table-4: Shifting gear to higher speed




6.2 For shifting gear to lower speed

Field test result

SR no Initial gear Manual gear

Changing

Automatic gear changing Gear changing

Pulses in sec Speed in km/hr From To

1 FOURTH 30 30 28 4TH 3RD

2 THIRD 25 22 20 3RD 2ND

3 SECOND 15 14 12 2ND 1ST

4 FIRST No shifting 8 1 NO SHIFTING

Table-4: Shifting gear to lower speed

7 CONCLUSIONS

1. This project is made with preplanning that provides a lot of practical knowledge regarding, planning, purchasing,

assembling and machining.

2. The application of electromagnetic produces smooth operation and operated electromagnetic gear shifting system it is very

much useful for two wheeler, car owner.

3. By using more techniques this design can be modified and developed according to application .this system is flexible and

can be implemented on a motor cycle available INDIAN market without any modification.

4. It working condition performed by the programmed embedded C codes in the microcontroller were optimized and were

the key source for changing gear system.

5. The motivation of this work is to implement this idea in clutch featured bikes with suitable clutch is controlled.

6. This project also helped us to know the periodic steps in completing a project work. And let to know the strength of team

work.




8 References

1) “Muthu raj. M ” Design and fabrication of button operated electromagnetic gear changer for four stroke petrol engine

two wheeler vehicle” Vol-2 Issue-3 2016

2) “Mr. Mayuresh N. Pote” “Automated Gear Transmission in Two Wheelers Using “Embedded System” Volume: 05 Issue:

08 | Aug 2018

3) “Ambar Gupta” “Automatic gear changing mechanism in two wheelers” Volume 4 – No.2, April 2017

4) “Vishnu P R” “Pneumatic gear transmission for two wheeler” Volume 21 Issue1-April 2016

5) “Abhijath B” “Automated manual transmission for two wheeler” Volume5 Issue3-march2016

6) “Vrushabh Arun Kitukale” “Automatic transmission system for motor cycle” Volume5 Issue3-march2017

7) “S Vijaykumar” “Fabrication of pneumatic gear changer”Volume4 Issue3-Jun2014

8) “Abu Osama” “Semi Automatic gear shifter based on pneumatic”ISSN (e):2250-3021, ISSN (p):2278-8719

9) “A.A.Jagtap” “Automated manual transmission for two wheeler” Issue2 ISSN 2395-1621, Nov 2015

10) “Abhishek Borse” “Automatic gear transmission system” Volume4 Issue2-Feb2016


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